KUKA SmartProduction

KUKA SmartProduction makes your production line ready for the future. By intelligently and securely connecting all manufacturing machines to the cloud, we increase your production efficiency and process quality in a sustainable manner.

KUKA SmartProduction as a software for intelligent networking

Production lines consist of numerous sensors, actuators, network components, and lots more. Virtually all these integrated “things” are potentially valuable information providers, since processes depend on the interaction of various components and peripheral properties. If the aim is to use data not only to optimize individual components, but also to increase process quality, they must be intelligently processed and visualized together. KUKA SmartProduction gives system operators access to the information of process-relevant machines for evaluation – in compliance, of course, with the highest security standards and clear data association.

The cloud as a central storage

KUKA SmartProduction ensures easy, seamless, and manufacturer-independent cross-sector linkage of all production machines in the cloud. Designed for maximum freedom, KUKA SmartProduction can be deployed across different hardware and software landscapes. KUKA solution’s standardized interfaces and future-proof architecture make it the ideal IoT platform for enterprises in all markets and sectors.

KUKA SmartProduction lets you easily digitize your processes and make them accesible via the cloud.

A new level of digitization

KUKA SmartProduction enables all enterprises to consistently digitize whole cells and production lines. It creates an interoperable network, in which micro services and Big Data analyses can be used to analyze and lastingly improve manufacturing efficiency, quality, and flexibility. With our open platform we offer component manufacturers, system integrators, and machine operators an additional channel for value-added services and applications for the manufacturing industry.

SmartProduction Cell with IIoT Platform

With a fully automated and networked robotic cell with two integrated Heller machining centers, KUKA connects the analog and digital world of smart production.

A KR 500 L480-3MT robot picks up cast components using pneumatic grippers and presents them to one of the Heller machining centers. After the components have been drilled and milled, they are deburred in the outer position by the robot and subsequently unloaded. To enable it to feed parts to both machining centers from a total of four supply stations, the robot is installed on the KL 1500-3 linear unit.

The connection to the digital world is established through the networking of all relevant components with each other and with the KUKA Cloud. This means that not just KUKA products are integrated into the SmartProduction environment, but also all other active components of the cell. The data are collected in the KUKA Connectivity Box and forwarded to the cloud.

Services such as authentication, data processing, predictive maintenance and evaluation of events are performed in the cloud. The interactive illustration below shows how all data from the machines, machining spindles, robots and tools are displayed in clearly structured dashboards. In this way, operators, maintenance personnel and management have a complete overview of the production process as well as full control – at any time and from any location.

SmartProduction View

The SmartProduction dashboard gives an overview of connected assets and their real-time conditions. It shows the cell mode (producing, seek advise, stopped), the target and the produced units so far.

The floor plan of the cell shows the location and status of each asset.

The asset explorer helps to get an overview of the health status of all assets of the cell.

The performance tile provides insights about the Overall Equipment Effectiveness (OEE) parameters and historical data. The OEE is calculated through quality, availability and performance.

Gripper

The status tile provides the health status and general information about your asset.

The service life tile gives an overview about the services status and precise maintenance information for all grippers.

The preventive maintenance tool counts the exact cycles for each gripper.

Machining / Material Handling

The status tile provides the health status and general information about your asset.

The raw/finished parts tile gives an overview of the numbers of the raw and finished parts of each turntable.

The floor plan of the cell shows the location and status of each turntable.

Configuration of the Industry 4.0 architecture

KUKA uses a modern, Industrie 4.0 architecture for networking the production cell with CNC machines from Heller. Simplified, this architecture can be regarded as comprising four layers: manufacturing components (systems), Edge Controller, IIoT platform and user interface.

Industrie 4.0 architecture

First layer – the manufacturing components

This layer consists of the real machines and sensors that are used in the production facility and networked with the cloud application. In the case of the “Heller cell”, these are machines from Heller Maschinenfabrik GmbH, KUKA AG, Zimmer Group and altran Group.

Second layer – the Edge Controller

It serves as a reliable communications interface between the production cell and the IIoT platform. Firstly, KUKA’s Edge Controller is capable of plug-and-play communication with the systems using modern standard protocols, such as OPC/UA or MQTT. Secondly, the Edge Controller can also be used for interfacing brownfield systems, as it is capable of modular expansion with individual protocols.

Third layer – the industrial IoT platform

The KUKA IIoT platform offers a wide range of typical industrial IIoT applications and services. The applications include asset management, condition monitoring and preventive maintenance. The IIoT services are ready-to-use modules for IIoT solutions, such as manufacturing machine learning, manufacturing analytics/big data, rule engines, event management and the creation of a workflow.

Fourth layer – the ergonomic user interface

The end user can access the user interface by logging on in the web browser, making it easy for the user to work with the data. The Heller cell is accessed via an overview screen, and the user can then navigate to the individual systems. In addition to the overview of the system status, functions such as a shop floor plan and the KPIs of the individual production cells are offered here. The user interfaces can be adapted flexibly to specific customer requirements.

At the end of the day, the question remains: what does the future hold for medium-sized engineering enterprises? With KUKA SmartProduction, KUKA paves the way for enterprises across all sectors to position themselves in the digital world. The challenge and chance for those enterprises is to seize the opportunities while not losing touch with own core competencies.